m r excava c llc no.1 / 2014 1 · 2017. 1. 4. · a magazine from atlas copco construction...

a magazine from atlas copco mining, rock excavation and construction llc – NO.1 / 2014 1

MECHANIZED ROCK EXCAVATION WITH ATLAS COPCO - NO. 1 / 2014

anchor drilling * line drilling * conexpo-con/agg

Atlas Copco remanufacturing brings used components back to OEM specifications

new Good as

“Reman, Service Exchange, Repair & Return

You can be confident that we will provide a quality product” TENNESSEE The Powercrusher PC3 makes fast work of recycled asphalt pavement. (page 7)

CONNECTiCuT The quarry that provided the Statue of Liberty her base, Stony Creek is still mining its famous granite. (page 14)

Contents issue 01/2014

PuBLiSHER Sofie Gielen, Marketing Communications DirectorEDiTOR-iN-CHiEF Scott Ellenbecker [email protected] www.atlascopco.us/magazines

PuBLiSHED By Mining, Rock Excavation and Construction LLC3700 E. 68th AvenueCommerce City, CO 80022TELEPHONE 800-732-6762WEB www.atlascopco.us

a maGazine from atlas copco mininG, rock excavation and construction llcM&C usa

Dave PietrzykowskiVP Parts & Service

LAS vEgAS Atlas Copco showcases new equipment at ConExpo/Con-Agg 2014. (page 17)

In this issue of M&C, you will read about something I’m particularly proud of—our approach to the aftermarket opportunity commonly referred to as “reman” or “remanufactured.” In my 25 years in the industry, I’ve noticed many different approaches to reman, and I think we excel in our approach.

At Atlas Copco, we refer to reman as a fixed-price, off-the-shelf component that has been rebuilt by a certified, trained technician to new OEM

specifications using genuine OEM parts. The customer is required to provide the replaced/failed component, or “core,” to recover a core charge and complete the transaction.

In addition to reman we offer a slightly different option called Service Exchange. We provide the customer a replacement reman component, and the customer pays only the actual cost of repairing the returned core.

Finally, we have the more common Repair & Return service, which may range from a total OEM remanufacture of the failed component to a repair process in which some parts can be reused.

Why is the availability of these offerings important? At Atlas Copco, we have listened to our customers. That’s why we offer different models of reman solutions.

You can be confident that we will provide a quality product, as an original equipment manufacturer. We are constantly tailoring our product portfolio to meet our customers’ needs, and our extensive research ensures we are properly positioned from a price point perspective.

Please call one of our helpful customer service reps at a local company-owned store or an authorized independent distributor. Or call 800-732-6762 to see how we can meet your surface or underground application requirements.

Thanks for your business.

READ uS ONLiNE www.atlascopco.com/cmtmagazines

a magazine from atlas copco construction technique – NO.1 / 2014 3

The Atlas Copco Scooptram ST18, an 18-tonne capacity underground load-haul-dump rig for development work and production mining, is now available. The Scooptram ST18 works well with the 60-tonne Minetruck MT6020 and com-pletes Atlas Copco’s range of underground LHDs in this segment.

The optimized bucket and unique boom design with load-sensing hydraulics and variable displacement pumps increase capacity and speed. Combined with the

IntroduCIng a new 18-MetrIC tonne LHd wItH best-In-CLass vIsIbILIty

3

wHere to fInd usPlease contact your nearest Atlas Copco Customer Center. Visit the store

website to see regional news and product information focused to its location.

For further in form a tion, please visit www.atlascopco.us

state CIty PHone websItega atlanta 888-762-3745 www.atlascopco.us/atlanta

md abingdon 410-485-3366 www.atlascopco.us/abingdon

pa clarks summit 800-950-1049 www.atlascopco.us/clarkssummit

co denver 866-466-9777 www.atlascopco.us/denver

nV elko 775-777-2204 www.atlascopco.us/elko

tn Knoxville 888-339-0344 www.atlascopco.us/knoxville

ma ludlow 413-589-7439 www.atlascopco.us/ludlow

fl miami 954-977-1041 www.atlascopco.us/miami

Wi milwaukee 414-760-1193 www.atlascopco.us/milwaukee

tn nashville 615-641-3000 www.atlascopco.us/nashville

az phoenix 623-780-0200 www.atlascopco.us/phoenix

ca sacramento 877-236-0415 www.atlascopco.us/sacramento

ca temecula 760-599-9299 www.atlascopco.us/temecula

az tucson 520-834-0400 www.atlascopco.us/tucson

Atlas Copco continues to expand its blasthole product offering with the addition of the reverse circulation (RC) kit for the DM45/50 midrange blasthole drill. The RC kit is designed to meet the demands of today’s expanding mining market by offering the added dimension of in-pit grade control.

A number of components are included with the optional kit, which can also be retrofitted on drills currently in the field.

The cyclone arm allows for sampling from the ground or platform level, with a vertical raise and lowering function. A 17-gallon dump box, with a steep cone for limiting sample hang up, is part of the sample collection feature. The primary and duplicate ports can easily be adjusted from 4 to 15 percent. The Reverse Circulation Carousel has four 4 ½-inch rod cups and offers a 145-foot maximum onboard capacity.

The DM45 and DML RC drill diameters range between 4 ½ inches to 5 ¾ inches, and also offers a 145-foot depth onboard capacity.

reverse CIrCuLatIon kIt for tHe dM45 and dML MId-range bLastHoLe drILLs

Atlas Copco Rig Control System that moni-tors, supports and controls all aspects of the operation, the ST18 provides better muck pile penetration, less wear and tear on the machine and an overall faster and more pro-ductive loading cycle.

• Automatic ride control and automaticdeclutch increase the lifespan and re-duce spillage

• Automatic traction control reduces tirewear and fuel consumption

news

• Soft stops on the boom, bucket andsteering reduce daily wear and tear

• Safety features include an automaticbrake test, protection guards, three-point access system, boom lockup, firesuppression systems and a machineprotection system

• Visibility is best in class even towardthe rear

• Radio remote control or semi-autono-mous control available

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4 a magazine from atlas copco mining, rock excavation and construction llc – NO.1 / 2014

newAs good as


Remanufacturing meets a need to lower operational costs and gives new life to used components

In multiple locations around the world, At-las Copco’s Mining and Rock Excavation Service division (MRS) has been investing in both new and existing service centers

focused on providing remanufac-tured components for customers.

At a time when mining com-panies are looking to increase rig availability and lower total op-eration cost, this is an excellent way to maximize assets and pro-vide cost flexibility to customers.

Atlas Copco’s Reman Center Garland (RCG), located in Gar-land, Texas, is the flagship loca-tion for remanufacturing equip-ment components. Processes and procedures developed in Garland are a model for the new stand-ardized processes around the world.

RCG is the main North Ameri-can facility for remanufacturing Atlas Copco Drilling Solutions machine components. Elko, Ne-vada, and Sudbury, Ontario, also have remanufacturing facilities to provide multiple services for Atlas Copco machines.

THE gARLAND FACiLiTy has come a long way since its startup in 2009. After a 24,000-square-foot expansion in 2012, the Center’s current 40,000-square-foot facil-ity is now equipped with state-of-the-art tools and testing equipment, including At-las Copco’s industrial tools and hydraulic testing tools. In its five work bays, RCG remanufactures rotary heads, air ends, pumps, motors and cylinders. Customers benefit from high off-the-shelf availability of these components.

RCG also allows customers to bring in their own components for repair as need-ed, or customers can send their idle com-ponents back to get credit. These flexible

business models make it eas-ier for customers to choose the service that best fits their needs.

Components sent to RCG are first evaluated for their suitability as remanufactur-ing candidates. Each com-ponent that qualifies for re-man goes through a specific 15-step process that includes inspection, disassembly, cleaning, upgrading, parts re-placement, assembly and test-ing. Each component leaving the RCG will have an OEM quality certificate and trace-able information, including serial number, parts numbers and inspector signatures.

Each component stays in the Atlas Copco system throughout its life. RCG Op-erations Manager Sylvia Havre-Carter said, “We’ve had components come in here multiple times. As long as we have a quality core, we can return it to original condi-tion with our highly quali-fied technicians following our strict processes.”

The RCG remans each component to its latest engineering specifi-cations, ensuring the component is brought up to current OEM specifications with the latest factory upgrades.

The RCG uses high-end Tensor elec-tronic assembly tools along with barcode-embedded work orders. Interactive software tracks and controls specifications of work performed, ensuring that everything meets OEM specifications, even how each bolt is tightened.

ONCE ASSEMBLED, products are rigor-ously tested on state-of-the-art test benches. Havre-Carter said, “With knowledgeable OEM-certified technicians using advanced

SyLviA HAvRE-CARTERReman Center Garland Operations Manager

BiLL XuANMarketing Manager, Atlas Copco Reman Solutions

This rotary head from a Pit viper 351 drill rig will be completely restored and reassembled using new genuine parts and applying the latest engineering specifications and factory upgrades.

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equipment, along with our assurance processes, we certainly deliver quality. We guarantee genuine OEM parts will be used on remanufactured components while offering a warranty that exceeds the Atlas Copco standard warranty.”

Bill Xuan, who is the product man-ager responsible for Atlas Copco Re-man Solutions, oversees the global roll-out process. He pointed out the greatest cost related to customers’ productivity is downtime. “Being down greatly out-

(left) The remanufacturing process begins with cleaning all components before moving through the five work bays. The procedures and processes developed in garland set the standard for Atlas Copco Reman Centers worldwide.

weighs the cost of the component itself, and a remanufactured com-ponent is even more cost effective with at least the same quality level as new. Having remanufacturing solu-tions for our customers allows them the peace of mind that major com-ponents are always available off the shelf.”

That is only the start of the ben-efits, Xuan said. “Having a single-source supplier and OEM-guaran-

teed remanufactured components along with continued service creates harmo-ny in using Atlas Copco equipment.”

Remanufacturing Solutions is an ef-fort to offer customers smart and sus-tainable options for service. Service is flexible and can be tailored to each customer’s needs, whether it is 24-hour tech support, routine maintenance, re-pairs, remanufacturing or service pro-grams that use Atlas Copco’s expertise to manage equipment fleets.

“Our goal is to be flexible in how we help customers and share knowledge,” Xuan said. “Atlas Copco understands customer operations and their industry, and how to maximize performance of their equipment. Atlas Copco’s tech-nicians at the mine can monitor the part’s life from installation to removal. Scheduled replacement means there is no downtime outside routine mainte-nance. We can look ahead for optimum planning for the customer or just pro-vide service as needed.”

Havre-Carter said that the customer can realize 30 to 50 percent savings us-ing remanufactured components versus new components. Considering labor, fuel consumption, logistics and inven-tory costs, customers realize more val-ue from Atlas Copco remanufactured components.

“We are continually focusing on improvements to our processes. Each technician has years of experience working on these components, and the step-by-step processes we’ve put in place only make us better as a team,” Havre-Carter said.

Havre-Carter wanted customers to know Atlas Copco cares about the pro-cess every step of the way. “Our team takes ownership of each component, and we are committed to the quality we send through the door.” ■


Hard roCkPaving company uses Atlas Copco Powercrusher PC3 to ramp up recycled asphalt stockpiles to rapF

or decades asphalt has been one of the most commonly recy-cled materials, with reclamation rates as high as 95 percent. The Hoover Inc. paving division of LaVergne, Tenn., likes to keep

plenty of reclaimed asphalt pavement (RAP) on hand and will stockpile sev-eral years’ worth in advance to keep it

readily available. A paving company’s investment cost in processing RAP from waste to a salable commodity assures regulators that it is destined for reuse. Therefore, Tennessee regulations will allow an asphalt company to stockpile 10 to 20 percent more RAP material, de-pending on the plant’s mix ratio, when the asphalt is first consistently crushed

and screened to a maximum acceptable reduction, which in this case was ⅜ inch minus.

Hoover has its own crushers at its Lebanon plant and quarry, but it wanted to expand its capabilities with a port-able crusher to help tackle a scheduled 14-month surge in RAP production for its stockpiles.

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Salesman Stacy Lynn of the Atlas Cop-co–Nashville store connected Hoover with a portable Atlas Copco Powercrusher PC3 impact crusher and Atlas Copco HCS 5515 screen.

In the first four months, the setup had al-ready contributed 120,000 tons to Hoover’s RAP reserves without a hitch.

Hoover maintenance technician Jes-sie Carney was impressed that the Power-crusher PC3 was doing so well: “I’m sur-prised it could go through all that we’ve fed it.”

Eric Amberson, Atlas Copco’s prod-uct line manager for Powercrushers in the U.S., said the PC3 does well with abrasive material such as RAP because it was de-signed as a primary crusher.

However, its high throughput rate begins before the box, at the vibratory hopper and conveyor feed. Fines are sifted down to the bottom and through its grizzly onto the main conveyor, significantly decreas-

ing the volume of abrasive material en-tering the chamber and bypassing the crusher box altogether.

The geometry of the box itself, Am-berson said, is that of a primary crush-er. The PC3 crushing chamber’s ca-pacity is created by its swing beams’ relationship to its rotor, which allows for larger feed sizes. The feed inlet is 4 feet by 2 feet 4 inches.

These factors combine to make the PC3 an effective crusher of highly

TOM HOOvER JR. Hoover Paving Manager

THOMAS LOvvORN Hoover Paving Superintendent

abrasive RAP. Amberson said, “It has a 250-ton per hour throughput rating, even at the reduction ra-tio an asphalt plant needs: for in-stance, ⅜ inch minus.”

The rating is based on actual 100 percent reduction throughput, not just an input rate or free-flow out-put rate, which Amberson noted should be considered during manu-facturer comparisons.

At the Lebanon site Hoover is

ERiC AMBERSONPowercrusher Product Manager

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keeping RAP to less than ¾ inch by running the PC3 with a ⅝-inch top screen and 9/16-inch bottom screen. Thomas Hoover Jr., grandson of found-er Ephraim Hoover and the paving di-vision operations manager, said Hoo-ver was seeing a production average of 200 tons an hour, though he added, “At times we’ve seen 350 tons an hour. That’s the difference between wet and dry. Moisture slows it down. It has been really wet the past few weeks.”

Asphalt also has an inherent tendency to cake on the screens, which worsens with heat and moisture. The HCS 5515 screen is adjustable to accommodate these material characteristics. Thomas Lovvorn, Hoover’s paving superinten-dent has occasionally run a batch of rock from the quarry through the PC3. “Cleans it right up,” he said.

He spread his hands about 2 feet apart to indicate the size of stone that was

dropped in the hopper. “It will take big rocks. Whatever you put in it is going to get ground,” he said. This gives Hoover the versatility to pro-duce aggregate as well as RAP.

The PC3 is powered by a 385 hp engine. Though diesel fuel had been in the $4 range, Hoover and Lov-vorn believed the cost of operating the crusher to be reasonable. The PC3 consumed about 12 gallons per hour totaling 75 gallons per 10-hour shift. The screener ran on 20 to 30 gallons of fuel per shift.

Hoover planned to have the Pow-ercrusher PC3 for about 14 months, during which time Atlas Copco would provide preventive mainte-nance and be on call if a problem should arise. Hoover said the stock-pile is expected to last them up to five years, depending on future pro-ject demands. ■

EPHRAiM HOOvER JR., a freight trans-portation provider, established Hoover Inc. in 1955. At that time President Eisen-hower’s vision of an interstate highway system was just getting started. Ephraim’s company had all the orders it could fill. In the beginning, these were crushed stone orders for concrete, asphalt paving and grading. The crushed stone operation con-tinues today but is joined now by Hoover’s own paving division. The paving division and its 300 employees provide municipal, state and federal construction services such as grading, drainage, asphalt pav-ing, base and surface construction, pave-ment marking and striping from five loca-tions in three states. Hoover also serves its commercial and industrial customer needs with building, mechanical, electrical, demolition, sewer and water line installa-tion services.

Three of Hoover’s hot mix asphalt plants are located in Tennessee and have their own quarries. Two more plants are located in Mississippi and Alabama.

ABOuT HOOvER iNC.


drilling in anew directionRepair of flood damage at Cumberland River Park calls for creative application of a Hütte 504 drilling rig’s unique ability to drill 45° beneath itself

https://www.youtube.com/watch?v=wLHTvAuj87U


“the Hütte 504 was the only drill its size with the power we needed, and it was the only drill we could find that could drill at this great an angle under its own tracks.”eric snyder, GeoFirma Owner

Tennesseans know it as Nash-ville’s Thousand Year Flood, the deluge brought on by a saturated weather front when it stalled over Central and Western Tennessee in early May 2010. It dropped up to 20 inches of rain in the span

of only a few days. It took weeks for the region’s affected

watersheds to drain themselves. Rivers such as the Cumberland hit all-time re-cords for cresting and flooding. Down-town, along what had been the Cumber-land’s steep banks, railroad tracks lay more than 6 feet under. And in Nash-ville the Grand Old Opry’s famous stage was 46 inches underwater.

Three years later, some restoration projects were still dealing with the dam-age. One was the retaining wall repair for Cumberland River Park, a new visi-tor site and playground along the shore-line between Titans Stadium and the Korean War Veterans Memorial Bridge. The wall had been pushed out and now

was leaning over the river. The ground it had been holding back to support a scenic overlook was sinking into the gap. To fix it, general contractor Blakley Construction Services, of Brentwood, Tenn., teamed up with GeoFirma, a Nashville-based contractor specializing in municipal and commercial geotechni-cal projects.

Michael Thomas, co-founder of Blak-ley Construction Services, explained Geofirma’s role in the repair. Blakley had installed new sheet piling, but be-fore cutting away the damaged retaining wall, GeoFirma was to drill and grout three stranded cable anchors 105 to 120 feet in drilling length, at 45 degrees in-to the bank, ensuring at least a 20-foot socket in the bedrock for additional sta-bility in the new retaining system.

gEOFiRMA OWNER Eric Snyder found a way to avoid the substantial time and cost that would have been invested in building a drilling platform in the river. If he could locate a compact yet pow-

erful crawler drill rig, he could drive it onto a temporary deck that would bridge the gap between the old and new piling.

Sales rep Stacy Lynn of the Atlas Copco‒Nashville store matched up Snyder with a Hütte HBR 504 hydraulic crawler drill and a 7 ⅝-inch Atlas Cop-co Symmetrix simultaneous drilling/casing advancement system with Sec-oroc QL 60 down-the-hole hammer. An Atlas Copco XRVS 1000 portable com-pressor fed air to the hammer at 1,000 cfm and 180 psi.

Snyder said: “The Hütte 504 was the only drill its size with the power we needed, and it was the only drill we could find that could drill at this great an angle under its own tracks. We want-ed to work from a bridge between the old sheet piles and the new. If we had tried to mount a drill to an excavator, we would easily be over 50,000 pounds. We’d have had to build a platform in the river to work from. The cost on that would have been exorbitant.”

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Although the Hutte weighs only 33,000 pounds and measures just 6 feet 9 inches wide, it still has 11,500 pounds of crowd force, 22,500 pounds of extraction force and more than 21,000 foot-pounds of torque.

SOiL CONDiTiONS BEHiND the sheet piling consisted of river rock and peb-bles of various sizes the first 85 feet. After cutting a hole in the old piling at the entry point, GeoFirma covered it temporarily with plywood to prevent cavitation. Snyder and his crew then went to work.

GeoFirma used the Symmetrix sys-tem to drill 7 ⅝-inch threaded cas-ing through 85 feet of unconsolidated ground and then 20 feet into bedrock. Then GeoFirma inserted stranded an-chors into the socket and cemented them with neat Portland grout simultane-ously with casing withdrawal. Snyder explained that he kept a 10-foot head on the cement in the casing as he with-drew it.

The unusual drilling angle made the casing and rod connections a unique challenge. In vertical drilling, Snyder said, he would simply have used the

winch to position sections of rod and casing. Instead, Snyder and Lynn de-vised a sling system to put each nested pair of 6.5-foot 3 ½-inch drill pipe and 7 ⅝-inch casing in place.

“We knew going in it was an ambi-tious project,” Snyder said. “There was concrete to go through, man-placed river gravel fill, then saturated silt and ultrafine flowing sands before hitting rock. Not to mention, between the pil-ings, you have that 20 feet of unsupport-ed drill string before you start drilling.”

Snyder said that without a simultane-ous drilling and casing advancement

From its perch atop a 20-foot-long platform spanning the gap between new and old sheet piling on the banks of the Cumberland river, the Hütte HBR 504 sits ready to drill the first of three 105-foot anchors. it was the only drill in its size with the power geoFirma needed for the job—as well as the only drill geoFirma found that could drill at a 45-degree angle back under itself.


(above) Stacy Lynn, of the Atlas Copco–Nashville store, is on site as geoFirma owner and driller Eric Snyder begins the first of three 105-foot anchors. The anchors consist of stranded cable grouted into a 20-foot rock socket in the Cumberland River Park Stabilization Project at the park’s scenic overlook.

(below) The morning sun greets both the Music City skyline and the Hütte 504.

system he would have either put a roll-er cone or drag bit in front of the cas-ing, “but using Elemex or Symmetrix made the most sense. We’re penetrat-ing the unknown without significantly disturbing it.”

As for choosing Atlas Copco over competitive versions of Elemex and Symmetrix, he said, “We did consider similar systems, but truthfully, I didn’t think they’d hold up.”

Snyder had started with Elemex and probably would have finished with it, he said, but Symmetrix was faster due to its slightly different configuration. Symmetrix’s bit protrudes farther than the ring bit. Elemex, which is designed for ultimate control of air, has its bit tucked back inside the ring bit.

When Atlas Copco representatives suggested he try Symmetrix, Snyder found that Symmetrix worked best for him in the complicated ground condi-tions, and he appreciated having that choice.

SyNDER EMPHASizED that his con-fidence to take on such difficult pro-jects comes from customer support. Snyder first met Lynn four years ago. “I was looking for a local source for all my geotechnical equipment and supplies: top hammer drills, hollow MAI bar, everything. That’s when I met Stacy. Atlas Copco has been in-tegral in the growth of our company. They’ve introduced us to new drill-ing techniques. On jobs where it was questionable which technique would be the best choice, they acted as con-sultants.

“Support from Atlas Copco is sec-ond to none. In this day and age, in this economy, customer service is eve-rything. When I needed hammer ser-vice, I just dropped it off at the end of the day. They stayed late, tore it down, cleaned it and had it back together ready for me in the morning. And it wasn’t just local support. Due to the difficulty of this job, they flew in a Symmetrix expert twice, as well as the top Hütte representative.”

Snyder said GeoFirma bought the Symmetrix system and QL 60 ham-mer and he was impressed enough with Hütte to purchase one. ■


rockstarRock Buggy line drills famous Stony Creek granite in Stony Creek, Conn.

After more than 150 years of op-eration, Stony Creek dimensional stone quarry has become just as famous as the sites that bear its stone.

In fact, its distinctive granite, sought for its attractive appearance and robust characteristics, can be

found at Grant’s Tomb, Grand Central Terminal, the Statue of Liberty, the Smithsonian Institute, the Brooklyn Bridge and countless corporate headquarters and government buildings, librar-ies, colleges, landmarks and memorials. The West Point Battle Memorial was carved from a single seamless slab 20 by 50 feet long. At 150 tons, it is regarded as the largest single granite monolith in the Western Hemisphere.

Although it is used for new construction, the stone is also used for matching to existing repairs and additions to buildings and bridges. Richard Atkinson, Stony Creek’s quarry superintendent, said it is one of best features of using the quarry’s product. “Take the Bulkeley Bridge project in Hartford, where some of the original stone was quarried in the early 1900s. During a recent re-habilitation project of the bridge, remnant blocks were found in the river that sat below the water for many years and were incorporated into a cur-rent project along with stone quarried just a year ago. You can’t tell the difference.”

WiTH TODAy’S MODERNizED machinery and stone-cutting techniques, Atkinson said the company has the capacity to supply as much

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stone in one month as would have taken the original quarrymen three years to supply. One of those is a quarry-special-ized mobile rock drill called the Rock Buggy.

In addition to its drill mast, it has an 11-foot drilling rail to ensure perfectly spaced holes required for precision line drilling, with the goal of having perfect-ly squared product, yielding minimal waste.

Stony Creek acquired it from Perfora, the original manufacturer, as ownership changed back in 2007. When Atlas Cop-co announced its acquisition of Perfora, which is called Stonetec in the U.S., he said he felt relief. During his 31 years with the quarry, Atkinson said Stony Creek was using Atlas Copco’s manual rock drills. He knew they had local cus-tomer centers and could provide imme-diate technical support.

STONy CREEk COuNTS on the Rock Buggy for the second and final stages of dimensional stone production: bench and block dressing, though it is also in-volved in primary cutting as well.

The first operation is to separate out a section of the bench about 100 feet long, 15 to 18 feet high and 21 to 25 feet deep. This is initiated the same as it has been done for years, by fire-blasting a groove at the ends of the 100-foot-long block with a rock-cutting torch.

The granite, which was formed in a molten state, flakes away under the torch’s force. This technique may soon give way to an Atlas Copco diamond wire cutting machine the quarry just finished demoing, the SpeedCut. “Just about everyone is going to wire saw-ing,” Atkinson said. “They’re a lot more fuel efficient, a lot quieter, and dust con-trol is much better.”

Then the block is vertically and hori-zontally drilled. For the most part the only time Stony Creek uses blasting is to split the stone from the formation, al-so known as the primary shot.

Blastholes are charged with prima-cord that provides the energy required

to pop the webbing between holes in the rock but also provides some cushion, Atkinson said. “We’re talking very con-trolled blasting here. It’s not like blast-ing to move overburden.”

A comparison might be the tap giv-en to scored glass to get a quick, clean separation along the burn. The bump to the granite must be hard enough to get a clean break but light enough not to cause any fractures in either the block or the rest of the bench.

ONCE THE BLOCk has been separated, it’s time to perforate and separate. “We still use feathers and wedges,” Atkinson said. “The same way it’s been done to

snap the blocks for thousands of years.” Atkinson said a typical example of

drilling might be a line of 8-foot holes drilled every 3 inches along the 11-foot rail. “We used to use cumbersome pneu-matic channel drills. The beauty of the Rock Buggy is how it moves around. It’s self-contained. We can use it for both blasting and for splitting.”

The target dimension is a 48,000-pound block, 11 by 6 by 4 feet in size, perfectly square. This is how it ships to customers.

NOT ONLy HAS THE stone been used throughout the U.S., but it is routinely sent to projects abroad. In the past ship-

Quarry staff include (from left) Richard Atkinson, Stacy Mancini, Tom Hixon and Darrell Petit.

Stony Creek granite slab Stony Creek granite block


ments have included Singapore, Germany, and Australia.

Atkinson said operations at Stony Creek have made little more than a dent in the formation accidental-ly discovered 150 years ago while preparing a railroad bed. The cur-rent operation is a 50-acre parcel surrounded by 400 acres of addi-tional property. Today the property is owned by the town of Branford, Conn., which leases it to the Stony Creek Quarry Corporation.

Of his company’s relationship with Atlas Copco, Atkinson said he expects a lot. For one, Matt Pe-terson, who is Atlas Copco’s Di-

mensional Stone Industry product line manager, used to work in the quarry himself. Atkinson laughed, “Yes, I’m expecting top quality service and tech support.”

But he added that he has faith in Atlas Copco. “Perfora didn’t have a strong U.S. support base,” Atkin-son explained. “I’d never heard of Perfora, but I’ve known Atlas Cop-co my whole career. They’ve been in drilling forever.”

With plenty of product and re-liable equipment to keep up with demand, Stony Creek’s future of continued production is written in stone. ■

THE ROCk Buggy’S maneuverability comes from two steering axles and four-wheel drive. It can be front-wheel or all-wheel steered, and it is capable of sideways and diagonal travel. A closed circuit Sauer Danfoss hydrostatic transmission gives soft starts and stops. It travels to and from the bench at up to 5.9 mph under power of its four-cylinder, 85 hp Cummins B 3.3 turbo-charged diesel engine.

Drilling operations are CAN-bus con-trolled, electronic over hydraulic. The op-erator works with a joystick and graphic display and has data recording capabilities. A remote control panel means the opera-tor can distance himself from the noise and dust of the immediate drilling environment, though dust collection is well managed by a hydraulically operated 206 cfm vacuum and auto-cleaning filter system.

Both vertical and horizontal drilling of 1 1/8- to 1 ¾ -inch holes are accomplished by 10-foot rods driven by a chain-fed choice of hydraulic drills, which slide on hardened steel inserts of an independent aluminum column attached to a 15-foot-9-inch articu-lated boom. Atlas Copco’s own drill offer-ing for the Rock Buggy is its COP 1132.

ABOuT THE ROCk Buggy

(Above left) Stony Creek granite is shown here on the Northwest Corner Building in Columbia university, New york City. (Design Architect: Rafael Moneo, Design Architect & Moneo Brock Studio, Design Project Architect; Executive Architect: Davis Brody Bond)

(Left) A Rock Buggy sets up for drilling at Stony Creek.

https://www.youtube.com/watch?v=x0UDN3t9itM


iT’S HEREIf it’s new, Atlas Copco at ConExpo-Con/Agg 2014

Atlas Copco invited kurt Busch to the show to test out his “driving” skills on a ROC drill simulator. Atlas Copco sponsors Busch as part of the Stewart-Haas race team. Atlas Copco Mining and Rock Excavation Service saw a lot of action on their simulator, which was open for anyone to try. Shown with Busch is trainer Wesley Stivers.

Product Manager Eric Amberson talks to ConExpo attendees about the virtues of the Powercrusher PC3 and HS1 screen.

The March 2014 ConExpo-Con/Agg show in Las Vegas hosted nearly 130,000 registered attendees representing 170 countries, up from 159 in 2011. Held every three years, the show is one of the largest in the construction and aggregates industry.

Atlas Copco, using the theme “Sustainable Productivity,” showcased its products in surface crawlers, crushing, tooling… and much more.


ConExpo attendees were interested in the fuel-saving features of the FlexiROC T45.

Atlas Copco showcased its drilling expertise at ConExpo.

There was much to see in rock drilling tools: from geotechnical core drilling options when a project starts to the many founda-

tion drilling options and tooling options for blasthole drill rigs both on the surface and in tunneling. Atlas Copco presented a full package of rock drilling tool options at ConExpo.

Bigger impact in a condensed package was certainly visible in the rock drilling tools display. The introduction of the new Secoroc COP 66 down-the-hole hammer was a featured product because

of its complete redesign and greater effi-ciency. And in the top hammer offering, the T-WiZ line grew with the T60 class expanding the threaded line to 6 inches.

Shorter than its predecessor, the COP 64 Gold, the new Secoroc COP 66 penetrates 15 percent faster, translating to less time over the hole and decreased fuel consumption. The hammer has fewer parts yet features the ability to rebuild the hammer twice in its life un-der normal drilling conditions. This all equates to a lower cost per foot over the life of the product.

The bit design is also unique because the COP 66 has no exhaust tube. The solid bit design features no center-flush-ing hole, making it easier to operate.


LATEST PRODuCT RELEASES FROM ATLAS COPCO AT CONEXPO

FLEXiROC T45 TOP HAMMER DRiLL Rig:

• Powerful 40 hp COP 3060, COP LOGIC Drill Control system that adjusts impact, feed and rotation pressures depending on the ground conditions to insure straight holes

• Fuel efficient—Consumes energy only as needed and with adjustable air flow

• Equipped with reverse camera

• Onboard diagnostics to assist in troubleshooting

• ROPS and FOPS certified cabin with great visibility in all directions without changing positions in the chair

MAX DEPTH ENgiNE HOLE SizE AiR

118 ft 325 hp 3½–5½ in 472 cfm

SECOROC COP 66 DOWN-THE-HOLE HAMMER:

• 15 percent faster penetration than its predecessor COP 64 Gold, more easily adjustable for feed force and rotation

• 30 percent shorter and lighter than earlier models

• No exhaust tube, no center flushing hole

• Longer service life – higher reliability

• Less wear and tear on the hammer

• E-kit allows two rebuilds with sustained performance in normal abrasive conditions

• Easily adjustable for feed force and rotation, making life easier for the operator

• Reduced air consumption and fewer parts

SECOROC gM RH HyDRAuLiC gRiNDER:

• Fully hydraulic powered – designed to be mounted on a surface crawler

• Simple to use, low noise levels

DRiLLiNg PARAMETERS

ROTATiON SPEED MAX. PRESSuRE

15–70 rpm 435 psi

AiR PRESSuRE AiR CONSuMPTiON SPEED SPiNDLE

87–100 psi 40 L/min 14,900 rpm


The increased drill capacity and longer service life of Atlas Copco drilling tools drew interest at ConExpo.

Business Line Manager of Rock Drill-ing Tools Gene Mattila said it best: “We have every tool a contractor would need to be more efficient on his project. Our engineers are constantly working on better and faster ways to drill a hole — of any size in any formation. We are a total solution source with a team of support to back up the products.”

THE FLEXiROC T45 drill rig was an attractive fixture at the booth because of its fuel efficiency. Field studies prove that the Tier 4 FlexiROC T45 with fixed boom uses half as much fuel as its prede-cessor using the same rock drill, depend-ing on rock conditions. Additionally, the new rock drill COP 3060 mounted on a fixed boom and aluminum feed manages large diameters using the T60 drill string with outstanding performance and reliability.

During operation, the operator can adjust the airflow and the dust collector fan speed according to actual working demands. The speed of the engine and compressor are then adjusted automati-cally.

The FlexiROC T45 has 50 percent fewer hoses and 70 percent fewer cou-plings compared to similar rigs on the market. The hydraulics and electrical components are positioned close to their

functions, making them easier to service and maintain and reducing the risk of leakage.

Maurice Hunter, business line man-ager of Surface and Exploration Drilling Equipment, said, “I’m excited about this new rig with its performance, reliability and mind-blowing fuel economy.”

Mario Santillan, product manager at Atlas Copco Surface Drilling, added: “It's an incredible accomplishment to increase productivity and drilling capacity while reducing fuel consumption so dramati-cally. Everybody wins when there's less environmental impact, a better working environment and higher profitability.”

Accompanying the FlexiROC T45 was the Secoroc T60 T-WiZ threaded tooling. With a bit diameter range from 3.6 to 6 inches, the T60 increases drilling capacity by offering up to 30 percent longer service life and boosts productivity by drilling more holes per shift. The T-WiZ product line improves reliability by wearing out before breakage and enhances utilization by reducing rod and shank changes.

Also on display for foundation drill-ers was the cluster drill, which is built with drilling diameters up to 120 inches, and the Secoroc QL 300 down-the-hole hammer.

Atlas Copco also featured its Power-crusher PC3 impact crusher with the

HS1 screen. This one-two punch combination was a hit with customers looking for the perfectly-sized crushed material in one unit. Adding less than 4 tons to the PC3’s operating weight, which is ideal for crushing recycled material, the HS1 screen sends larger material back to the hopper until it’s minimized to the desired size. This crush-screen combination is a perfect example of how Atlas Copco can really put power to work and offer sustain-able productivity. ■


SECOROC T60 T-Wiz TOPHAMMER EQuiPMENT:

• Up to 30% longer service life

• Easy uncoupling

• Faster penetration rates

• Tough thread system with greater stability

• Fewer rod changes

• Pair T-WiZ with Secoroc top hammer bits

• More holes per shift

• Available sizes: 3.6″ – 6″

SECOROC 17 ½ BiT THiRD Bi62C (PRv):

• Hard rock cutting structure

• Drills faster and stays in the hole longer

• Longer cutting structure and bearing life

• Pressure-compensated lubrication system

• Random cutting structure

• Proven bearing and seal packages

DiAMETER MAX. CuTTiNg RADiuS MODELS AvAiLABLE

17 ½ in 8 in 6 ¾–17 ½ in

SECOROC DiRT DiggER PDC DRiLL BiTS:

• Smoother drilling operations and increased penetration rates

• Force-balanced PDC cutter locations minimize bit whirl and drill precise holes

• Asymmetric blade design reduces harmonics

• Longer bit life

• Designed with economical steel

• Optimized cutter distribution

• Sizes: 3″-12 ¼″

SECOROC REvERSE CiRCuLATiON BiT:

• Sizes available: 5 3/8″, 5 1/2″, 5 5/8″, 5 3/4″, 6″, 6 1/2″

SECOROC kLAW-STyLE HOLE OPENER:

• Utilizes random cutting structure bit thirds for precisely positioned load distribution

• Maximize cutter count for hard applications

• Forward/rear taper if required

• Wide range of manufacturer threads in variety of shaft diameters

LATEST PRODuCT RELEASES FROM ATLAS COPCO AT CONEXPO

Powercrusher PC3

Atlas Copco Dynapac rollers such as the CA2500 soil roller and the CT3000 tamping compactor are intelligent additions to mine and quarry fleets where roads, berms and pits need efficient compaction.

Atlas Copco’s Construction Equipment offerings also include handheld and hydraulic attachment breakers, pumps, compressors, generators, light towers and many more tools and pieces of equipment for aggregate and mining operations.


LaunCH Padpit viper311Atlas Copco puts the latest in blasthole series on the market

Atlas Copco continues to in-novate with the release of the Pit Viper 311 large range rotary blasthole drill. The PV-311 has the capability to drill 9- to12 ¼-inch holes with a clean hole, single-pass

depth of 65 feet. The single-pass PV-311 incorporates

many qualities of the rest of the Pit Viper line with new innovations that further lower the cost of drilling. The proven Rig Control System (RCS) gives the PV-311 a strong technology foundation to bring serviceability and drilling accuracy to the front lines of the mining process.

The single-pass Pit Viper 311 is the first of the 310 series. The Pit Viper 316, a multi-pass version of the Pit Viper 310, will be released later in 2014. The Pit Viper 316 will drill to a depth of 295 feet

using a five-rod carousel with 50-foot drill pipe.

Existing models in the Pit Viper lineup include the PV-235, PV-271, PV-275 and PV-351. The new series of 310s signifies the optimal hole size—310 millimeters (or a 9- to 12 ¼-inch range).

The new PV-311 rig’s single-pass depth capacity is 65 feet or 135 feet with two additional 35-foot rods in the stan-dard internal carousel.

The Atlas Copco marketing and design team focused on maintainability and high productivity by keeping proven systems from other Pit Vipers, while improving some features.

Project Manager Iain Peebles said, “Our design plan targeted lifespan sav-ings for the customer with everything from fuel to maintenance.”

At the project’s beginning, Atlas Copco

listened to the customers who wanted lower costs and high production capac-ity. “We build a new rig from the tower down. We design to capacity, depth and hole size, then match to the length and size of the tower and work down to bal-ance and tracks,” said Peebles.

TOWER DESigN changes will benefit customers in many ways. Product Man-ager for Large Blasthole Drills Maureen Bohac pointed out changes in the new PV-311 tower that benefit the customer, specifically the maintenance departments. “Because we have a deeper tower we can increase the size of the sheaves, which incorporates sealed bearings and operates with our auto-tensioning feature. All that adds up to increased cable and sheave life, plus this system requires less mainte-nance,” said Bohac.

https://www.youtube.com/watch?v=IslugRFcqNghttp://www.atlascopco.us/usus/products/navigationbyproduct/product.aspx?id=3507166&productgroupid=1495175


pit viperBohac said the new rotary head now

operates with larger 7-cubic-inch motors that offer better lubrication for increased spline and main bearing life. Through the use of a variable displacement pump and motors, the operator has an infinite selec-tion (over the system’s range) of rotation speeds at variable torque values, up to 13,000 ft-lb of torque.

Service work around the new tower will be easier, too. Technicians will have the benefit of an access hatch that fully encloses the fiber-grate catwalk along the length of the tower. Although there are no open floor spaces in the grating, techni-cians have the benefit of a full restraint system that allows them to clip their harnesses to the cable and walk freely throughout the tower area without having to disconnect for cable fasteners.

THE Pv-310 SERiES offers several options in its single- and multi-pass ver-sions, starting with the engine offering. To match a mine’s preference for brand and regulatory demands, Tier 4 engines are available with the Cat C32 and MTU 16V2000, and the Tier 2 options are Cat C32, MTU 16V2000 and Cummins QSK38.

In the future both electric and diesel options will be available.

Air compressors are available in low pressure models. “PV-310 comes standard with low pressure 3,000 cfm air compressors,” said Bohac.

An optional feature first developed for the PV-235 is also available on the new PV-311. An Atlas Copco engineer-ing team at Drilling Solutions developed and co-patented a revolutionary power control clutch system focused on saving energy. The system allows the operator to turn off the compressor with the push of a button when not in use. To engage the clutch, the operator hits a button on the chair’s control panel to switch the air off as he begins to trip out of the hole.

Other optional features include auto-level, auto rod changing and tele-remote operation. Additional packages are avail-able including auto-drilling and GPS hole navigation.

Productivity is improved with low-tech

features, too. The PV-311 holds up to 1,400 gallons of fuel (with 1,200 gallons of water) and 1,900 gallons of water (when optioned with 700 gallons of fuel). A mine can maximize its service crew schedules because a rig can operate a full 24 hours before fluid replenishment.

THE CAB is the result of a year and a half of engineer-ing that incorporates utility and comfort with high-tech control.

The operator commands the drill rig in quiet comfort. In the center of the cab un-der a wall-to-wall heavy duty removable mat and shaded windows, the operator’s seat offers a full view of the platform and work area.

Peebles said, “We put a lot of time and creature comforts into this new cab, but it is funny how many drillers have com-mented on something as simple as the integrated shades.”

High-tech features include color touchscreens that feed drilling data to the operator while additional safety monitors show movement from a ground surveillance system and video feeds from closed-circuit television cameras.

Operators will enjoy the convenience of an optional refrigerator and microwave while they hum along to their favorite music fed through the USB connection. They will stay cool even in the world’s hottest mines with the 3.5-ton air condi-tioner.

The cab’s central electronics cabinet offers benefits to the maintenance techni-cian. Service access doors open from floor to ceiling, giving full access to all electronics. The well-lit cabinet allows open spaces for technicians to maintain the existing equipment and add technol-ogy as needed.

Bohac said the new PV-311 will be a great fit for mines all over the world in both coal and metal applications. ■

iAiN PEEBLESProject Manager

MAuREEN BOHACProduct Manager, Large Blasthole Drills

The Pit viper 311 has easy access to ground level service.

we never stopWe are always researching, developing and trying harder to bring you the finest equipment. With its ability to drill precise patterns with single-pass or multi-pass drilling, the Pit Viper 311 is just the latest example.

800-732-6762www.atlascopco.com/blastholedrills

Ellenbecker Communications 30124 State Hwy 264 Round Lake, MN 56167 USA

PRSRT STDU.S. POSTAGE PAIDSPRINGFIELD, MAPERMIT NO. 935

m r excava c llc no.1 / 2014 1 · 2017. 1. 4. · a magazine from atlas copco construction...

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